US4432800A - Beneficiating kiln dusts utilized in pozzolanic reactions - Google Patents
Beneficiating kiln dusts utilized in pozzolanic reactions Download PDFInfo
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- US4432800A US4432800A US06/408,173 US40817382A US4432800A US 4432800 A US4432800 A US 4432800A US 40817382 A US40817382 A US 40817382A US 4432800 A US4432800 A US 4432800A
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Classifications
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- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B18/00—Use of agglomerated or waste materials or refuse as fillers for mortars, concrete or artificial stone; Treatment of agglomerated or waste materials or refuse, specially adapted to enhance their filling properties in mortars, concrete or artificial stone
- C04B18/04—Waste materials; Refuse
- C04B18/16—Waste materials; Refuse from building or ceramic industry
- C04B18/162—Cement kiln dust; Lime kiln dust
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02W—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO WASTEWATER TREATMENT OR WASTE MANAGEMENT
- Y02W30/00—Technologies for solid waste management
- Y02W30/50—Reuse, recycling or recovery technologies
- Y02W30/91—Use of waste materials as fillers for mortars or concrete
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10S—TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10S106/00—Compositions: coating or plastic
- Y10S106/01—Fly ash
Definitions
- This invention relates to pozzolanic reactions and particularly to pozzolanic reactions involving fly ash and kiln dust with and without a filler.
- the present invention is directed to a method of beneficiating separated or conditioned kiln dusts which are less reactive because of having been separated from the total kiln dust or because they have been conditioned or because they have been separated and conditioned.
- the method of beneficiating separated or conditioned kiln dusts which have insufficient reactive properties to produce desired pozzolanic reactions comprises adding small amounts of a material selected from the group consisting of CaO, calcium hydroxide and sodium hydroxide.
- the beneficiated dusts can be utilized with fly ash or fly ash and a filler to produce pozzolanic reactions and provide a durable mass.
- the solid waste generated by cement manufacture is primarily kiln dust.
- dust contains a mixture of raw kiln feed, partly calcined material, finely divided cement klinker and alkaline and alkali carbonates and sulfates (usually sulfates).
- alkali content of the returned dust is too high for the product clinker to meet specifications, the dust must be discarded.
- Up to about 15% of the raw materials processed may be collected as dust and of this about half may be low enough in alkalis to be returned to the kiln.
- the rest usually stockpiled as a waste material which usually is discarded and may be a nuisance and possibly a hazard.
- the major oxides found in a cement kiln dust are: SiO 2 , Al 2 O 3 , Fe 2 O 3 , CaO, MgO, So 3 , Na 2 O and K 2 O.
- typical cement kiln dusts may have the following analyses:
- the solid waste generated by line manufacture is primarily lime stack dust.
- This dust contains a mixture of raw kiln feed, partly calcined material, and finely divided material. There is no value in returning the dust to the kiln, as it is too fine and passes directly through to the precipitator again. Up to about 15% of the raw materials processed may be collected as dust. It is usually stockpiled as a waste material which usually is discarded and may be a nuisance and possibly a hazard.
- lime stack dust typically, the major oxides found in lime stack dust are: CaO, MgO, SO 3 , CO 2 and Available Free Lime.
- typical lime stack dusts may have the following analyses:
- finely ash as used in connection with stabilized bases is well known and as used herein is intended to indicate the finely divided ash residue produced by the combustion of pulverized coal or lignite, which ash is carried off with the gases exhausted from the furnace in which the coal is burned and which is collected from these gases usually by means of suitable precipitation apparatus such as electrical precipitators.
- suitable precipitation apparatus such as electrical precipitators.
- Those finely pulverized ashes resulting from combusion of oil and from combustion of waste materials in a large incinerator or natural pozzolan can also be utilized in the methods described herein providing their chemical compositions are resonably similar to pulverized coal fly ashes.
- fly ash so obtained is in a finely divided state such that usually at least 70% by weight passes through a 200-mesh sieve, although incinerator ashes may be considerably coarser. Fly ash may be considered an "artificial pozzolan", as distinguished from a "natural pozzolan”.
- aggregate as used in connection with load supporting compositions is also well known and refers to natural or artificial inorganic materials most of which are substantially chemically inert with respect to fly ash and lime, and substantially insoluble in water.
- aggregate may comprise limestone, dolostone sand, blast furnace slag, gravel, synthetic aggregate and other similar material.
- Aggregates can comprise a wide range of types and gradations, including sands, gravels, crushed stones, and several types of slag. Aggregates should be of such gradation that, when mixed with cement kiln dust, fly ash and water, the resulting mixture is mechanically stable under compaction equipment and capable of being compacted in the field to high density.
- the aggregate should be free from deleterious organic or chemical substances which may interfere with the desired chemical reaction between the cement kiln dust, fly ash and water. Further, the aggregate should preferably consist of hard, durable particles, free from soft or disintegrated pieces.
- sludges can be used as fillers and can be stabilized or chemically fixed.
- Typical sludges are sulfur scrubbing sludges from power plants, waste water treatment sludges from municipal sewage plants and industrial waste sludges.
- the percentages of filler set forth herein as being by dry weight include the liquid content of the sludge.
- kiln dusts which have lesser reactivity can be beneficiated to produce a desired pozzolanic reaction by mixing the kiln dust, pozzolan such as fly ash and filler and water and adding a small amount of a material selected from the group consisting of CaO, calcium hydroxide and sodium hydroxide. It has been found that the addition of small amounts of these materials will sufficiently beneficiate the kiln dust so that when the kiln dust is mixed with a pozzolan such as fly ash or fly ash and a filler such as aggregate or sludge, a desired pozzolanic reaction will be achieved.
- a pozzolan such as fly ash or fly ash and a filler such as aggregate or sludge
- the additions are made to the mixture just prior to the use of the kiln dusts, that is, when water is added to the mixture of kiln dust and fly ash or the mixture of kiln dust, fly ash and filler.
- pozzolan 6-24%
- the additives used were quicklime (CaO), powdered, technical grade calcium oxide; hydrated lime (Ca(OH) 2 ), powdered, reagent grade calcium hydroxide, and sodium hydroxide (NaOH), certified ACS grade pellets.
- the additive was mixed with about two-thirds the estimated volume of water needed for the mix.
- quicklime or sodium hydroxide was used the slurry was allowed to cool to room temperature before adding the dry blend of cement kiln dust, fly ash, and aggregate.
- Cement kiln dusts are classified as follows: (1) Marginal; (2) Separated; (3) Conditioned and (4) Separated and Conditioned.
- Marginal dusts are those which develop low compressive strength during initial testing or when used in mixes without additives.
- Separated dusts are those which have been passed through mechanical or electrostatic precipitators. During processing, the coarser particles are separated in the first or early stages. Usually these particles are recycled in the kiln. The second or tertiary, etc., stages generally are composed of the finer and finer fractions that become the waste dusts.
- Conditioned dusts are those which may be treated at the plant or in the laboratory.
- the waste dust is treated with a controlled amount of water (typically 10-15% by weight) to facilitate handling and storage and to ensure compliance with environmental regulations.
- a controlled amount of water typically 10-15% by weight
- 12 percent by weight of water is added to dusts.
- Mixing is performed with the batch mixer utilizing the same modified bread hook as is used for mixing batches for the strength tests. Mixing time is five minutes, and large balls are broken by hand during initial mixing, whereas the smaller balls produced during mixing are not broken up.
- the ducts are then stored in a plastic pail open at the top for free access to air and moisture.
- Separated and Conditioned dusts are those dusts which have an origin similar to separated dusts except they have been treated with a controlled amount of water.
- lime kiln dusts were studied and can be classified as High-Calcium and Dolomitic dusts. It is believed that the high calcium lime kiln dust should have a limit of approximately 5 percent MgO (3% would be more desirable but it is deemed impracticable at this stage). In contrast, dolomitic lime kiln dusts exhibit MgO content in excess of 5%. However, magnesian kiln dusts were omitted purposefully from this classification because no dusts of this MgO composition (5-20%) were tested.
- Cylinders were made and tested in accordance with ASTM Standard C-593. These cylinders were enclosed in two self-sealing plastic bags and were held in an oven for seven days at 100° F. ⁇ 3°. At the end of the cure, the cylinders were soaked in water for four hours, and were capped and tested.
- the vacuum saturation cylinders were also cured at 100° F. ⁇ 3° for seven days. These cylinders at the end of the curing period were allowed to cool to room temperature, and were placed in a vacuum of 24 inches Hg for 30 minutes. After this time, they were flooded with water and were soaked in water for 60 minutes, and then they were capped and tested.
- the Tables 1 through 19 have been arranged to list the compressive and vacuum saturation strengths and moisture content data for mixtures of kiln dust, fly ash, and aggregate with and without the additives. In addition, these tables also list average compressive and vacuum saturation strengths, the average moisture contents of mixtures of fly ash, aggregate and powdered CaCO 3 .
- the CaCO 3 admixtures were made to exhibit the strength development only caused by the reaction of lime with the fly ash.
- the compressive and vacuum saturation strength data are listed in the tables and are designed as follows:
- Strength "C”--strength of 8-8-84 mixture of powdered CaCO 3 was used in place of kiln dust, but mixed with fly ash, and aggregate, and a specified amount of an additive.
- A is the compressive (CS) or the vacuum (VS) strengths with an additive.
- B is the compressive or the vacuum strengths without an additive.
- C is the compressive or the vacuum strengths using CaCO 3 as a blank or control to measure only the strength effect of the additive.
- E is the positive or negative effect of the additive on the strengths of the admixtures. This effect hereafter will be designated a negative or positive “synergistic effect.”
- the cylinder strengths for the mixture without additives ranged from 580 to 635 psi, whereas cylinder strengths with the addition of CaO ranged from 1050 to 1590 psi. Both strengths for batches with the addition of Ca(OH) 2 ranged from 1010 to 1250 psi.
- the range of values of "synergistic effects" for the compressive (CS) and vacuum saturation (VS) strengths for each amount of additive follow:
- the cylinder strengths for the mixture without additives ranged from 675 and 725 psi, whereas strengths for the addition of CaO ranged from 1110 to 1810 psi.
- Strengths for batches with the addition of Ca(OH) 2 ranged from 1215 to 2045 psi.
- the range of values of the "synergistic effects" for the compressive (CS) and vacuum saturation (VS) strengths for each amount of additive follow:
- the cylinder strengths for the mixture without additive ranged from 1065 to 1130 psi, whereas the cylinder strengths with the addition of CaO ranged from 1355 to 1925 psi. Cylinder strengths with the addition of Ca(OH) 2 ranged from 1155 to 1775 psi.
- the range of "synergistic effects" for the compressive (CS) and vacuum saturation (VS) strengths for each amount of additive follow:
- the cylinders of this mixture without additives did not develop strength.
- the cylinders were the addition of CaO ranged from 0* to 1560 psi, whereas the cylinder strengths with the addition of Ca(OH) 2 ranged from 275 to 1365 psi.
- the range of values of the "synergistic effects" for the compressive (CS) and vacuum saturation (VS) strengths for each amount of additive follow:
- the cylinder strengths for the mixtures without additives ranged from 355 to 490 psi, whereas the cylinder strengths with the addition of CaO ranged from 1165 to 1420 psi.
- Cylinder strengths with the addition of Ca(OH) 2 ranged from 730 to 1525 psi.
- the range of values of the "synergistic effects" for the compressive (CS) and vacuum saturation (VS) strengths for each amount of additive follow:
- This material is a separated kiln dust conditioned in the laboratory for 31 days.
- the cylinders made with this lab conditioned dust without additive showed the 515 psi strength, whereas the cylinder strengths made with unconditioned dust without additive ranged from 915 psi (a Cincinnati fly ash from Monier Resources was used) to 1130 psi (a St. Albans fly ash from Pozzolanic, Inc., was used).
- 915 psi a Cincinnati fly ash from Monier Resources was used
- 1130 psi a St. Albans fly ash from Pozzolanic, Inc.
- Cylinders made with this dust were tested only for compressive strength.
- the cylinders made without additive developed a compressive strength of 145 psi.
- the average compressive strengths for cylinders made with the addition of CaO ranged from 630 to 1615 psi, whereas the average strengths for the addition of Ca(OH) 2 ranged from 935 to 1060 psi.
- the values of the "synergistic effect" for the compressive strength for each amount of additive follow:
- the average cylinder strengths of this mixture without additives ranged from 975 to 1035 psi, whereas the average strengths for the addition of CaO ranged from 875 to 1690 psi.
- the cylinder strengths with the addition of Ca(OH) 2 ranged from 645 to 885 psi.
- the range of values of the "synergistic effects" for the compressive (CS) and vacuum saturation (VS) strengths for each amount of additive follow:
- the average cylinder strengths for this batch without additives ranged from 1085 to 1315 psi, whereas strengths with the addition of CaO ranged from 675 to 1080 psi. Cylinder strengths with the addition of Ca(OH) 2 ranged from 960 to 1880 psi.
- the range of values of the "synergistic effects" for the compressive (CS) and vacuum saturation (VS) strengths for each amount of additive follow:
- This dust was conditioned in the laboratory for 14.1 weeks.
- the compressive strength of the mixture made with the lab conditioned dolomitic lime kiln dust without additive is 395 psi, whereas the compressive strength of the mixture made with unconditioned dust without additive is 1035 psi.
- Addition of 0.75% CaO increases the strength to 1240 psi, resulting in a "synergistic effect" for this lab conditioned dust of 500 psi.
- Cylinders made with this dust without additives exhibited strengths which ranged from 595 to 1405 psi, whereas strengths of cylinders made with the addition of CaO ranged from 1255 to 1810 psi. Strength of cylinders made with the addition of Ca(OH) 2 ranged from 995 to 1585 psi.
- the range of "synergistic effects" for the compressive (CS) and vacuum saturation (VS) strengths for each amount of additive follow:
- This dust was lab conditioned for 16 weeks.
- the compressive strengths of cylinders made with the lab conditioned, high calcium lime kiln dust without additive averaged 1145 psi, whereas the compressive strengths of cylinders made with unconditioned dust, but without an additive, average 595 psi.
- Addition of 0.75% CaO increased the cylinder strength to 1795 psi. This resulted in a "synergistic effect" for this lab conditioned dust of 305 psi.
- Cylinders made without additives did not develop strength.
- the cylinder strengths with the addition of CaO ranged from 455 to 610 psi, whereas cylinder strengths with the addition of Ca(OH) 2 ranged from 390 to 765 psi.
- the "synergistic effect" data for the compressive (CS) and vacuum saturation (VS) strengths for each amount of additive follow:
- the CaO slurry was added by two methods. In the first method, the slurry was allowed to cool for 20 minutes before it was added to the mix. In the second method, the CaO was mixed with water for one minute before it was added to the mix. The cylinder strengths of the mixture without additives averaged 650 psi. The cylinder strengths of the mixture with 0.75% CaO averaged 1815 psi for the 20 minute cooling time, and 1580 psi for the one minute cooling time. The "synergistic effect" for the compressive strength of cylinders with the addition of 0.75% CaO was 820* psi (20 minutes) and 585* psi (one minute).
- Cylinders of an 8-8-84 admixture of these components developed a strength of 210 psi. However, no strength developed for the mixture without additive. A control mixture (CaCO 3 as a substitute for kiln dust) with a 0.50% NaOH addition was not made, therefore no "synergistic effect" can be calculated.
- moisture content affects the degree of compaction and the calculated dry unit weight (density) of the compacted mixture. Furthermore, the moisture content also affects the water-cement ratio which in turn affects the degree of cementitious reactions in the mix.
- ASTM C593 was used as a guide in carrying out the compressive strength tests reported herein. However, making and handling cylinders made from mixtures containing more than 40% water required changes from the procedures described in ASTM C593 regarding compaction, demolding, and curing.
- the sludge was weighed into the mixing bowl and was homogenized using a paddle attached to a planetary drive. The kiln dust and fly ash were added and thoroughly mixed before adding the CaO slurry. The mixture was mixed for an additional three minutes after the addition of the slurry.
- the cylinders were filled by pouring the mixture into the mold, and shaking the mold and moving a knife through the mixture to eliminate voids.
- the mixture was cured inside the mold at room temperature.
- a plastic bag was fitted around the open end of the mold and was held in place by rubber bands.
- the cylinders were removed from the molds after curing for seven days, and were placed inside two self-sealing plastic bags for the remainder of the cure.
- the firm cylinders (those hard enough so that they could not be idented by finger pressure) were capped with molten sulfur capping compound. All cylinders were then tested for compressive strength.
- the average moisture content of the desulfurization sludge was determined to be 64.8% on a wet basis.
- the moisture contents of the cylinders are also reported on a wet basis, whereas the moisture contents of the other cylinders in the previously described tests are reported on a dry basis.
- the following table lists the compressive strength for each cylinder. It also lists the machine load for each cylinder; the cross-sectional area; the wet unit weight (density); and the moisture content (wet basis). The dry unit weight was not calculated because the objective was to bind chemically some of the water.
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Abstract
Description
__________________________________________________________________________ TYPICAL CHEMICAL ANALYSES FOR CEMENT KILN STACK DUSTS Source Source Source Source Source Source Source Source Source Source Average Ingredient I II III IV V VI VII VIII IX X % __________________________________________________________________________ SiO.sub.2 17.6 9.9 22.1 11.2 13.0 22.4 14.8 14.6 14.7 15.5 15.6 Al.sub.2 O.sub.3 4.4 3.1 4.7 3.2 4.0 10.0 3.4 3.4 3.7 4.0 4.4 Fe.sub.2 O.sub.3 2.0 1.2 1.8 1.4 5.0 4.1 2.2 2.2 3.0 1.5 2.4 CaO 39.6 47.6 63.7 48.8 47.2 19.4 47.3 46.3 46.5 43.2 44.9 MgO 2.0 1.3 2.6 2.1 1.2 0.6 2.1 2.0 2.0 2.1 1.8 SO.sub.3 3.8 0.9 1.1 2.4 13.6 10.1 4.8 5.0 8.2 5.0 5.7 Na.sub.2 O 0.2 0.1 0.2 0.2 0.4 1.3 0.9 0.9 0.8 0.3 0.5 K.sub.2 O 2.6 1.1 1.3 4.2 2.9 14.1 4.1 5.1 3.0 3.1 4.2 Loss on 26.6 31.6 2.5 26.6 12.9 13.2 21.1 21.4 18.2 23.9 19.8 Ignition __________________________________________________________________________
______________________________________ RANGE OF TYPICAL CHEMICAL ANALYSES FOR CEMENT KILN STACK DUSTS Ingredient Low % High % Mid-Range ______________________________________ SiO.sub.2 9.9 22.4 16.2 Al.sub.2 O.sub.3 3.1 10.0 6.5 Fe.sub.2 O.sub.3 1.2 5.0 3.1 CaO 19.4 63.7 41.5 MgO 0.6 2.6 1.6 SO.sub.3 1.1 13.6 7.3 Na.sub.2 O 0.1 1.3 0.7 K.sub.2 O 1.1 14.1 7.6 Loss on 2.5 31.6 17.1 Ignition ______________________________________
______________________________________ CHEMICAL ANALYSES OF DOLOMITIC LIME KILN DUSTS FOR MAJOR OXIDES AND FREE (AVAILABLE) LIME Free Sample Loss on (Available) No. CaO MgO S CO.sub.2 Ignition Lime SO.sub.3 ______________________________________ 1 43.39 29.82 0.80 22.30 24.60 17.58 -- 2 37.54 27.10 -- 17.72 26.99 10.98 3.43 3 35.86 26.20 -- 12.84 30.15 8.29 4.99 4 35.85 32.03 0.77 21.5 34.66 8.63 -- 5 43.42 32.24 0.82 13.0 22.92 20.17 -- 6 35.86 25.99 0.41 21.8 36.38 7.96 -- 7 39.50 30.02 0.74 17.58 26.78 15.58 -- 8 35.58 25.39 0.23 18.96 35.78 8.68 -- 9 40.90 30.02 0.78 11.02 24.46 15.54 -- 10 39.22 25.99 0.95 22.2 -- 11.43 -- 11 37.54 28.00 0.60 19.00 -- 13.22 -- 12 35.99 27.80 1.20 -- 31.86 9.75 -- 13 40.62 30.72 0.62 -- 25.53 16.58 -- Mean 38.55 28.56 0.70 17.99 29.10 12.64 -- Max 43.42 32.24 1.02 22.30 36.38 20.17 -- Min 35.58 25.39 0.23 11.02 22.92 8.29 -- Range 7.84 6.85 0.79 11.28 13.46 11.88 -- Mid- 39.50 28.81 0.62 16.66 29.65 14.23 -- Range ______________________________________
__________________________________________________________________________ CHEMICAL ANALYSES OF DOLOMITIC LIME KILN DUST SHOWING MAJOR AND MINOR OXIDES AND FREE (AVAILABLE) LIME Sample PERCENT Source Free No. SiO.sub.2 Al.sub.2 O.sub.3 Fe.sub.2 O.sub.3 CaO MgO SO.sub.3 K.sub.2 O Na.sub.2 O LOI Lime __________________________________________________________________________ 14 9.2 5.3 6.8 28.5 20.5 6.4 0.5 0.2 18.2 34.0 15 2.5 0.7 0.9 31.2 23.5 2.8 0.1 0.0 37.4 5.1 16 0.6 0.1 0.6 35.6 23.8 0.9 0.0 0.0 36.2 2.9 17 6.4 1.4 0.7 35.1 21.5 0.0 0.1 0.0 35.3 2.0 Mean 4.7 1.9 2.2 32.6 22.3 2.5 0.2 >0.1 31.8 11.0 Maximum 9.2 5.3 6.8 35.6 23.5 6.4 0.5 0.2 37.4 34.0 Minimum 0.6 0.1 0.6 28.5 20.5 0.0 0.1 0.0 18.2 2.0 Range 8.6 5.2 6.2 7.1 3.0 6.4 0.4 0.2 19.2 32.0 Mid Range 4.9 2.7 3.7 32.0 22.0 3.2 0.3 0.1 27.8 18.0 __________________________________________________________________________ Note: Free (available) Lime is listed for convenience and is not part of the oxide analyses.
__________________________________________________________________________ CHEMICAL ANALYSES OF HIGH CALCIUM LIME KILN DUST FOR MAJOR AND MINOR OXIDES AND FREE (AVAILABLE) LIME Sample PERCENT Source Free No. SiO.sub.2 Al.sub.2 O.sub.3 Fe.sub.2 O.sub.3 CaO MgO SO.sub.3 K.sub.2 O Na.sub.2 O LOI Lime __________________________________________________________________________ 1 9.9 4.2 2.0 54.5 0.5 8.0 0.2 0.0 14.2 26.4 2 10.1 4.9 1.4 44.3 3.6 4.8 0.4 0.1 27.5 2.6 3 1.9 0.5 0.4 66.1 2.2 1.7 0.1 0.0 19.6 40.8 4 3.4 1.8 0.8 56.7 1.1 0.3 0.2 0.0 34.4 13.1 5 3.2 1.2 3.5 58.0 0.4 2.2 0.1 0.0 27.6 14.5 6 12.7 4.8 1.4 62.4 0.7 2.0 0.2 0.1 8.4 29.7 Mean 6.9 2.9 2.1 57.0 1.4 3.2 0.2 >0.1 22.0 21.2 Maximum 10.1 4.9 3.5 66.1 3.6 8.0 0.4 0.1 34.4 40.8 Minimum 1.9 0.5 0.4 44.3 0.4 0.3 0.1 0.0 8.5 2.6 Range 8.2 4.4 3.1 21.8 3.2 7.7 0.3 0.1 25.9 38.2 Mid Range 6.0 2.7 2.0 55.2 2.0 4.2 1.6 >0.1 21.4 21.7 __________________________________________________________________________ Note: Free (available) Lime is listed for convenience and is not part of the oxide analyses.
A-B-C=±E
TABLE 1 __________________________________________________________________________ (Marginal Dust) AMOUNT OF STRENGTH MOISTURE MOISTURE MOISTURE ADDITIVE "A" CONTENT % STRENGTH "B" CONTENT % STRENGTH "C" CONTENT "E" __________________________________________________________________________ 0.25% CaO 1050 (CS) 9.3 580 (CS) 9.2 205 (CS) 8.6 265 0.50% CaO 1435 (CS) 9.3 580 (CS) 9.2 575 (CS) 9.2 280 0.50% CaO 1290 (VS) 9.3 635 (VS) 9.6 495 (VS) 8.5 160 0.75% CaO 1475 (CS) 10.6 580 (CS) 9.2 345 (CS) 11.3 550 0.75% CaO 1450 (VS) 10.9 635 (VS) 9.6 320 (VS) 13.8 495 1.14% CaO 1590 (CS) 11.0 580 (CS) 9.2 665 (CS) 10.3 345 1.14% CaO 1390 (VS) 9.8 635 (VS) 9.6 440 (VS) 10.4 315 1.50% CaO 1360 (CS) 9.9 580 (CS) 9.2 665 (CS) 11.1 115 1.50% CaO 1235 (VS) 18.8 635 (VS) 9.6 730 (VS) 7.7 -130 0.75% Ca(OH).sub.2 1250 (CS) 9.7 580 (CS) 9.2 170 (CS) 13.5 500 0.75% Ca(OH).sub.2 1195 (VS) 9.2 635 (VS) 9.6 320 (VS) 12.2 240 1.50% Ca(OH).sub.2 1010 (CS) 11.8 580 (CS) 9.2 260 (CS) 12.7 170 1.50% Ca(OH).sub.2 1105 (VS) 12.2 635 (VS) 9.6 400 (VS) 11.2 70 3.0% Ca(OH).sub.2 1065 (CS) 10.7 580 (CS) 9.2 595 (CS) 11.8 -110 3.0% Ca(OH).sub.2 1110 (VS) 10.6 635 (CS) 9.6 415 (VS) 12.4 60 0.75% CaO 1410 (CS) 5.9 235 (CS) 8.2 345* (CS) 11.3 830 __________________________________________________________________________ *The cylinders containing CaCO.sub.3 as a substitute for kiln dust used Trenton Channel Fly ash.
TABLE 2 __________________________________________________________________________ (Marginal Dust) AMOUNT OF STRENGTH MOISTURE MOISTURE MOISTURE ADDITIVE "A" CONTENT % STRENGTH "B" CONTENT % STRENGTH "C" CONTENT "E" __________________________________________________________________________ 0.76% CaO 1110 (CS) 7.2 675 (CS) 10.2 345 (CS) 11.3 90 0.75% CaO 1515 (VS) 9.9 725 (VS) 7.4 320 (VS) 13.8 470 1.14% CaO 1435 (CS) 7.8 675 (CS) 10.2 665 (CS) 10.3 95 1.14% CaO 1810 (VS) 9.3 725 (VS) 7.4 440 (VS) 10.4 645 1.50% CaO 1395 (CS) 10.5 675 (CS) 10.2 665 (CS) 11.1 55 1.50% CaO 1600 (VS) 9.4 725 (VS) 7.4 730 (VS) 7.7 145 0.75% Ca(OH).sub.2 1265 (CS) 10.7 675 (CS) 10.2 170 (CS) 13.5 420 0.75% Ca(OH).sub.2 1215 (VS) 10.6 725 (VS) 7.4 320 (VS) 12.2 170 1.50% Ca(OH).sub.2 2045 (CS) 9.7 675 (CS) 10.2 260 (CS) 12.7 1110 1.50% Ca(OH).sub.2 1700 (VS) 10.1 725 (VS) 7.4 400 (VS) 11.2 575 3.0% Ca(OH).sub.2 1540 (CS) 11.7 675 (CS) 10.2 595 (CS) 11.8 270 3.0% Ca(OH).sub.2 1510 (VS) 11.7 725 (VS) 7.4 415 (VS) 12.4 370 __________________________________________________________________________
TABLE 3 __________________________________________________________________________ (Marginal Dust) AMOUNT OF STRENGTH MOISTURE MOISTURE STRENGTH MOISTURE ADDITIVE "A" CONTENT % STRENGTH "B" CONTENT % "C" CONTENT "E" __________________________________________________________________________ 0.38% CaO 220 (CS) 11.6 FS (NO VALUE) (CS) 7.0 245 (CS) 11.6 -25 0.76% CaO 900 (CS) 6.3 FS (NO VALUE) (CS) 7.0 345 (CS) 11.3 555 1.14% CaO 820 (CS) 11.8 FS (NO VALUE) (CS) 7.0 665 (CS) 10.3 155 0.75% Ca(OH).sub.2 435 (CS) 8.2 FS (NO VALUE) (CS) 7.0 170 (CS) 13.5 265 1.50% Ca(OH).sub.2 360 (CS) 11.8 FS (NO VALUE) (CS) 7.0 260 (CS) 12.7 100 __________________________________________________________________________ FS Cylinder fell apart in 4 hour water soak.
TABLE 4 __________________________________________________________________________ (Conditioned Dust) MOISTURE MOISTURE MOISTURE AMOUNT OF CONTENT CONTENT STRENGTH CONTENT ADDITIVE STRENGTH "A" % STRENGTH "B" % "C" % "E" __________________________________________________________________________ 0.25% CaO 160 (CS) 10.6 FS (NO VALUE) (CS) 205 (CS) 8.6 -45 0.25% CaO BC (NO VALUE) 11.5 FVS (NO VALUE) (VS) 215 (VS) 9.1 -215 (VS) 0.50% CaO 340 (CS) 11.4 FS (NO VALUE) (CS) 575 (CS) 9.2 -235 0.50% CaO 670 (VS) 10.1 FVS (NO VALUE) (VS) 495 (VS) 8.5 175 0.76% CaO 1030 (CS) 13.7 FS (NO VALUE) (CS) 12.1 345 (CS) 11.3 685 0.75% CaO 675 (VS) 9.3 FVS (NO VALUE (VS) 9.4 320 (VS) 13.8 355 1.14% CaO 1180 (CS) 12.9 FS (NO VALUE) (CS) 12.1 665 (CS) 10.3 515 1.14% CaO 800 (VS) 9.8 FVS (NO VALUE) (VS) 9.4 440 (VS) 10.4 360 1.50% CaO 1095 (CS) 11.2 FS (NO VALUE) (CS) 12.1 665 (CS) 11.1 430 1.50% CaO 1560 (VS) 10.7 FVS (NO VALUE) (VS) 9.4 730 (VS) 7.7 830 0.75% Ca(OH).sub.2 585 (CS) 11.1 FS (NO VALUE) (CS) 12.1 170 (CS) 13.5 415 0.75% Ca(OH).sub.2 275 (VS) 9.4 FVS (NO VALUE) (VS) 9.4 320 (VS) 12.2 -45 1.50% Ca(OH).sub.2 660 (CS) 11.5 FS (NO VALUE) (CS) 12.1 260 (CS) 12.7 400 1.50% Ca(OH).sub.2 820 (VS) 9.6 FVS (NO VALUE) (VS) 9.4 400 (VS) 11.2 420 3.0% Ca(OH).sub.2 975 (CS) 12.5 FS (NO VALUE) (CS) 12.1 595 (CS) 11.8 380 3.0% Ca(OH).sub.2 1365 (VS) 10.5 FVS (NO VALUE) (VS) 9.4 415 (VS) 12.4 950 __________________________________________________________________________ BC Cylinder broke while removing from capper. FS Cylinder fell apart in 4 hour water soak. FVS Cylinder crumbled while placing in vacuum saturation sample support.
TABLE 5 __________________________________________________________________________ (Conditioned Dust) AMOUNT OF STRENGTH MOISTURE MOISTURE MOISTURE ADDITIVE "A" CONTENT % STRENGTH "B" CONTENT % STRENGTH "C" CONTENT "E" __________________________________________________________________________ 0.75% CaO 1230 (CS) 8.0 490 (CS) 11.4 345 (CS) 11.3 395 0.75% CaO 1420 (VS) 7.6 355 (VS) 11.7 320 (VS) 13.8 745 1.14% CaO 1350 (CS) 11.4 490 (CS) 11.4 665 (CS) 10.3 195 1.14% CaO 1165 (VS) 11.0 355 (VS) 11.7 440 (VS) 10.4 370 1.50% CaO 1395 (CS) 10.2 490 (CS) 11.4 665 (CS) 11.1 240 1.50% CaO 1405 (VS) 9.7 355 (VS) 11.7 730 (VS) 7.7 320 0.75% Ca(OH).sub.2 1105 (CS) 8.4 490 (CS) 11.4 170 (CS) 13.5 445 0.75% Ca(OH).sub.2 1205 (VS) 9.1 355 (VS) 11.7 320 (VS) 12.2 530 1.50% Ca(OH).sub.2 990 (CS) 9.6 490 (CS) 11.4 260 (CS) 12.7 240 1.50% Ca(OH).sub.2 730 (VS) 17.1 355 (VS) 11.7 400 (VS) 11.2 -25 3.0% Ca(OH).sub.2 1400 (CS) 10.8 490 (CS) 11.4 595 (CS) 11.8 315 3.0% Ca(OH).sub.2 1525 (VS) 10.7 355 (VS) 11.7 415 (VS) 12.4 755 __________________________________________________________________________
TABLE 6 __________________________________________________________________________ (Separated and Conditioned Dust) AMOUNT OF STRENGTH MOISTURE MOISTURE STRENGTH MOISTURE ADDITIVE "A" CONTENT % STRENGTH "B" CONTENT % "C" CONTENT "E" __________________________________________________________________________ 0.75% CaO 880 (CS) 11.5 FS (NO VALUE) (CS) 7.8 345 (CS) 11.3 535 0.75% CaO 920 (VS) 11.1 FV (NO VALUE) (VS) 11.5 320 (VS) 13.8 600 1.14% CaO 1215 (CS) 12.1 FS (NO VALUE) (CS) 7.8 665 (CS) 10.3 550 1.14% CaO 1035 (VS) 10.3 FV (NO VALUE) (VS) 11.5 440 (VS) 10.4 595 1.50% CaO 1260 (CS) 10.4 FS (NO VALUE) (CS) 7.8 665 (CS) 11.1 595 1.50% CaO 1230 (VS) 12.8 FV (NO VALUE) (VS) 11.5 730 (VS) 7.7 500 0.75% Ca(OH).sub.2 650 (CS) 11.2 FS (NO VALUE) (CS) 7.8 170 (CS) 13.5 480 0.75% Ca(OH).sub.2 705 (VS) 11.3 FV (NO VALUE) (VS) 11.5 320 (VS) 12.2 385 1.50% Ca(OH).sub.2 1220 (CS) 11.9 FS (NO VALUE) (CS) 7.8 260 (CS) 12.7 960 1.50% Ca(OH).sub.2 1155 (VS) 11.7 FV (NO VALUE) (VS) 11.5 400 (VS) 11.2 755 3.0% Ca(OH).sub.2 1415 (CS) 11.5 FS (NO VALUE) (CS) 7.8 595 (CS) 11.8 820 3.0% Ca(OH).sub.2 1215 (VS) 11.5 FV (NO VALUE) (VS) 11.5 415 (VS) 12.4 800 __________________________________________________________________________ FS Cylinder fell apart in 4 hour water soak. FV Cylinder fell apart in one hour water soak.
TABLE 7 __________________________________________________________________________ (Separated and Conditioned Dust) AMOUNT OF STRENGTH MOISTURE MOISTURE MOISTURE ADDITIVE "A" CONTENT % STRENGTH "B" CONTENT % STRENGTH "C" CONTENT "E" __________________________________________________________________________ 0.38% CaO 630 (CS) 11.4 145 (CS) 10.8 245 (CS) 11.6 240 0.76% CaO 1125 (CS) 10.2 145 (CS) 10.8 345 (CS) 11.3 635 1.14% CaO 1615 (CS) 8.0 145 (CS) 10.8 665 (CS) 10.3 805 0.75% Ca(OH).sub.2 1060 (CS) 10.4 145 (CS) 10.8 170 (CS) 13.5 745 1.50% Ca(OH).sub.2 935 (CS) 11.3 145 (CS) 10.8 260 (CS) 12.7 530 __________________________________________________________________________
TABLE 8 __________________________________________________________________________ (Separated Dust) AMOUNT OF STRENGTH MOISTURE MOISTURE MOISTURE ADDITIVE "A" CONTENT % STRENGTH "B" CONTENT % STRENGTH "C" CONTENT "E" __________________________________________________________________________ 0.25% CaO 1645 (CS) 9.1 1130 (CS) 9.5 205 (CS) 8.6 310 0.25% CaO 1610 (VS) 9.1 1065 (VS) 9.7 215 (VS) 9.1 330 0.50% CaO 1830 (CS) 8.8 1130 (CS) 9.5 575 (CS) 9.2 125 0.50% CaO 1720 (VS) 9.0 1065 (VS) 9.7 495 (VS) 8.5 160 0.75% CaO 1715 (CS) 9.7 1130 (CS) 9.5 345 (CS) 11.3 240 0.75% CaO 1655 (VS) 10.2 1065 (VS) 9.7 320 (VS) 13.8 270 1.14% CaO 1415 (CS) 9.4 1130 (CS) 9.5 665 (CS) 10.3 -380 1.14% CaO 1540 (VS) 9.0 1065 (VS) 9.7 440 (VS) 10.4 35 1.50% CaO 1925 (VS) 9.3 1130 (CS) 9.5 665 (CS) 11.1 130 1.50% CaO 1355 (VS) 10.2 1065 (VS) 9.7 730 (VS) 7.7 -440 0.75% Ca(OH).sub.2 1230 (CS) 10.8 1130 (CS) 9.5 170 (CS) 13.5 -70 0.75% Ca(OH).sub.2 1155 (VS) 9.6 1065 (VS) 9.7 320 (VS) 12.2 -230 1.50% Ca(OH).sub.2 1455 (CS) 7.5 1130 (CS) 9.5 260 (CS) 12.7 65 1.50% Ca(OH).sub.2 1385 (VS) 7.6 1065 (VS) 9.7 400 (VS) 11.2 -80 3.0% Ca(OH).sub.2 1775 (CS) 9.1 1130 (CS) 9.5 595 (CS) 11.8 50 3.0% Ca(OH).sub.2 1285 (VS) 11.6 1065 (VS) 9.7 415 (VS) 12.4 -195 __________________________________________________________________________
TABLE 9 __________________________________________________________________________ (Dolomitic Lime Kiln Dust) AMOUNT OF STRENGTH MOISTURE MOISTURE MOISTURE ADDITIVE "A" CONTENT % STRENGTH "B" CONTENT % STRENGTH "C" CONTENT "E" __________________________________________________________________________ 0.75% CaO 965 (CS) 8.7 1035 (CS) 10.2 345 (CS) 11.3 -415 0.75% CaO 1690 (VS) 8.6 975 (VS) 9.4 320 (VS) 13.8 +395 1.14% CaO 1440 (CS) 10.7 1035 (CS) 10.2 665 (CS) 10.3 -260 1.14% CaO 1330 (VS) 9.0 975 (VS) 9.4 440 (VS) 10.4 -85 1.50% CaO 1030 (CS) 10.0 1035 (CS) 10.2 665 (CS) 11.1 -670 1.50% CaO 875 (VS) 7.0 975 (VS) 9.4 730 (VS) 7.7 -830 0.75% Ca(OH).sub.2 645 (CS) 9.4 1035 (CS) 10.2 170 (CS) 13.5 -560 0.75% Ca(OH).sub.2 825 (VS) 10.7 975 (VS) 9.4 320 (VS) 12.2 -470 1.50% Ca(OH).sub.2 745 (CS) 9.5 1035 (CS) 10.2 260 (CS) 12.7 -550 1.50% Ca(OH).sub.2 885 (VS) 10.7 975 (VS) 9.4 400 (VS) 11.2 - 490 3.0% Ca(OH).sub.2 785 (CS) 8.2 1035 (CS) 10.2 595 (CS) 11.8 -845 3.0% Ca(OH).sub.2 725 (VS) 8.6 975 (VS) 9.4 415 (VS) 12.4 -665 __________________________________________________________________________
TABLE 10 __________________________________________________________________________ (Dolomitic Lime Kiln Dust) AMOUNT OF STRENGTH MOISTURE MOISTURE MOISTURE ADDITIVE "A" CONTENT % STRENGTH "B" CONTENT % STRENGTH "C" CONTENT "E" __________________________________________________________________________ 0.75% CaO 1040 (CS) 10.6 1315 (CS) 10.8 345 (CS) 11.3 -620 0.75% CaO 1050 (VS) 9.3 1085 (VS) 11.5 320 (VS) 13.8 -355 1.00% CaO* 785 (CS) 10.4 1315 (CS) 10.8 665 (CS)** 10.3 -1195 1.00% CaO* 735 (VS) 4.5 1085 (VS) 11.5 440 (VS)** 10.4 -790 1.50% CaO 675 (CS) 11.5 1315 (CS) 10.8 665 (CS) 11.1 -1305 1.50% CaO 1080 (VS) 9.0 1085 (VS) 11.5 730 (VS) 7.7 -735 0.75% Ca(OH).sub.2 1580 (CS) 10.2 1315 (CS) 10.8 170 (CS) 13.5 +95 0.75% Ca(OH).sub.2 1180 (VS) 7.3 1085 (VS) 11.5 320 (VS) 12.2 -225 1.50% Ca(OH).sub.2 1570 (CS) 15.3 1315 (CS) 10.8 260 (CS) 12.7 -5 1.50% Ca(OH).sub.2 960 (VS) 9.7 1085 (VS) 11.5 400 (VS) 11.2 -525 3.0% Ca(OH).sub.2 1880 (CS) 9.7 1315 (CS) 10.8 595 (CS) 11.8 -30 3.0% Ca(OH).sub.2 1520 (VS) 9.3 1085 (VS) 11.5 415 (VS) 12.4 -20 __________________________________________________________________________ *The Cylinders were made with an addition of 1.00% CaO before the decisio was made to use additions of 1.14% CaO. **CaO addition of 1.14%.
TABLE 11 __________________________________________________________________________ (High Calcium Lime Kiln Dust) AMOUNT OF STRENGTH MOISTURE MOISTURE MOISTURE ADDITIVE "A" CONTENT % STRENGTH "B" CONTENT % STRENGTH "C" CONTENT "E" __________________________________________________________________________ 0.75% CaO 1790 (CS) 10.3 2500 (CS) 9.8 345 (CS) 11.3 -1055 0.75% CaO 1855 (VS) 10.4 3330 (VS) 10.1 320 (VS) 13.8 -1795 1.14% CaO 1460 (CS) 11.5 2500 (CS) 9.8 665 (CS) 10.3 -1705 1.14% CaO 2225 (VS) 12.1 3330 (VS) 10.1 440 (VS) 10.4 -1545 1.50% CaO 1850 (CS) 10.8 2500 (CS) 9.8 665 (CS) 11.1 -1315 1.50% CaO 2680 (VS) 11.9 3330 (VS) 10.1 730 (VS) 7.7 -1380 0.75% Ca(OH).sub.2 2185 (CS) 9.2 2500 (CS) 9.8 170 (CS) 13.5 -485 0.75% Ca(OH).sub.2 1935 (VS) 9.5 3330 (VS) 10.1 320 (VS) 12.2 -1715 1.50% Ca(OH).sub.2 1895 (CS) 9.1 2500 (CS) 9.8 260 (CS) 12.7 -865 1.50% Ca(OH).sub.2 1760 (VS) 8.1 3330 (VS) 10.1 400 (VS) 11.2 -1970 3.0% Ca(OH).sub.2 1395 (CS) 11.0 2500 (CS) 9.8 595 (CS) 11.8 -1700 3.0% Ca(OH).sub.2 1350 (VS) 11.2 3330 (VS) 10.1 415 (VS) 12.4 -2395 __________________________________________________________________________
TABLE 12 __________________________________________________________________________ (High Calcium Lime Kiln Dust) AMOUNT OF STRENGTH MOISTURE MOISTURE MOISTURE ADDITIVE "A" CONTENT % STRENGTH "B" CONTENT % STRENGTH "C" CONTENT "E" __________________________________________________________________________ 0.75% CaO 1475 (CS) 8.8 595 (CS) 9.4 345 (CS) 11.3 535 0.75% CaO 1810 (VS) 9.1 1405 (VS) 9.2 320 (VS) 13.8 85 1.14% CaO 1255 (CS) 10.1 595 (CS) 9.4 665 (CS) 10.3 -5 1.14% CaO 1580 (VS) 9.8 1405 (VS) 9.2 440 (VS) 10.4 -265 1.50% CaO 1485 (CS) 9.6 595 (CS) 9.4 665 (CS) 11.1 225 1.50% CaO 1585 (VS) 9.5 1405 (VS) 9.2 730 (VS) 7.7 -550 0.75% Ca(OH).sub.2 1480 (CS) 10.0 595 (CS) 9.4 170 (CS) 13.5 715 0.75% Ca(OH).sub.2 1570 (VS) 9.6 1405 (VS) 9.2 320 (VS) 12.2 -155 1.50% Ca(OH).sub.2 1585 (CS) 9.1 595 (CS) 9.4 260 (CS) 12.7 730 1.50% Ca(OH).sub.2 1235 (VS) 10.3 1405 (VS) 9.2 400 (VS) 11.2 -570 3.0% Ca(OH).sub.2 995 (CS) 11.0 595 (CS) 9.4 595 (CS) 11.8 -195 3.0% Ca(OH).sub.2 1390 (VS) 9.5 1405 (VS) 9.2 415 (VS) 12.4 -430 __________________________________________________________________________
TABLE 13 __________________________________________________________________________ AMOUNT OF MOISTURE MOISTURE MOISTURE ADDITIVE STRENGTH "A" CONTENT % STRENGTH "B" CONTENT % STRENGTH "C" CONTENT "E" __________________________________________________________________________ Lime kiln dust from Dravo Lime Co. (Maysville, Ky.) coarse lime kiln dust. Lab conditioned for 16 weeks. (High Calcium Lime Kiln Dust) 0.75% CaO 1795 (CS) 8.8 1145 (CS) 10.2 345 (CS) 11.3 305 Lime kiln dust from Martin-Marietta (Woodville, Ohio) from Poz-O-Pak Plant Lab conditioned 14.1 weeks. (Dolomitic Lime Kiln Dust) 0.75% CaO 1240 (CS) 10.5 395 (CS) 10.0 345 (CS) 11.3 500 Cement kiln dust from Columbia Cement (Zanesville, Ohio) Precipitator dust. Lab conditioned 31 days. (Separated Cement Kiln Dust) 0.75% CaO 1220 (CS) 11.0 515 (CS) 10.2 345 (CS) 11.3 360 River Cement (Festus, Mo) (Conditioned 36 days) (Marginal Cement Kiln Dust) 0.75% CaO 1370 (CS) 9.5 270 (CS) 9.9 345 (CS) 11.3 755 __________________________________________________________________________
TABLE 14 __________________________________________________________________________ AMOUNT OF STRENGTH MOISTURE MOISTURE STRENGTH MOISTURE ADDITIVE "A" CONTENT % STRENGTH "B" CONTENT % "C" CONTENT "E" __________________________________________________________________________ 0.75% CaO 455 (CS) 13.0 (FS) (NO VALUE) (CS) 11.7 345 (CS) 11.3 110 0.75% CaO 575 (VS) 12.1 (FS) (NO VALUE) (CS) 11.7 320 (VS) 13.8 255 3.0% CaO 610 (CS) 12.4 (FS) (NO VALUE) (CS) 11.7 ND ND ND 0.75% Ca(OH).sub.2 390 (CS) 13.8 (FS) (NO VALUE) (CS) 11.7 170 (CS) 13.5 220 0.75% Ca(OH).sub.2 475 (CS) 10.8 (FS) (NO VALUE) (CS) 11.7 170 (CS) 13.5 305 1.50% Ca(OH).sub.2 765 (CS) 12.8 (FS) (NO VALUE) (CS) 11.7 260 (CS) 12.7 505 1.50% Ca(OH).sub.2 670 (VS) 12.1 (FS) (NO VALUE) (CS) 11.7 400 (VS) 11.2 270 3.0% Ca(OH).sub.2 675 (CS) 16.2 (FS) (NO VALUE) (CS) 11.7 595 (CS) 11.8 80 __________________________________________________________________________ FS--Cylinder fell apart in four hour water soak. ND--Not determined.
TABLE 15 __________________________________________________________________________ AMOUNT OF MOISTURE MOISTURE MOISTURE ADDITIVE STRENGTH "A" CONTENT % STRENGTH "B" CONTENT % STRENGTH "C" CONTENT "E" __________________________________________________________________________ 0.76% CaO 1385 (CS) 8.4 840 (CS) 10.6 345 (CS) 11.3 200 1.14% CaO 1420 (CS) 8.5 840 (CS) 10.6 665 (CS) 10.3 -85 __________________________________________________________________________
TABLE 16 __________________________________________________________________________ AMOUNT OF MOISTURE MOISTURE MOISTURE ADDITIVE STRENGTH "A" CONTENT % STRENGTH "B" CONTENT % STRENGTH "C" CONTENT "E" __________________________________________________________________________ 0.25% CaO 1745 (CS) 10.3 1510 (CS) 7.0 205 (CS) 8.6 30 0.25% CaO 1900 (VS) 9.8 1510 (CS)* 7.0 215 (VS) 9.1 175 0.50% CaO 2285 (CS) 8.8 1510 (CS) 7.0 575 (CS) 9.2 200 0.50% CaO 2215 (VS) 9.0 1510 (CS)* 7.0 495 (VS) 8.5 210 __________________________________________________________________________ *This value is compressive strength rather than vacuum saturation strength.
TABLE 17 __________________________________________________________________________ AMOUNT OF MOISTURE MOISTURE MOISTURE ADDITIVE STRENGTH "A" CONTENT % STRENGTH "B" CONTENT % STRENGTH "C" CONTENT "E" __________________________________________________________________________ Cement kiln dust from Lone Star Industries (Dixon, Ill.) 1.0% NaOH 830 (CS) 8.5 (FS) 7.0 455 (CS) 11.4 375 (NO VALUE) (CS) Cement Kiln dust from River Cement (Festus, Mo.) 1.0% NaOH 1360 (CS) 9.0 675 (CS) 10.2 455 (CS) 11.4 230 Cement kiln dust from Lone Star Industries (Bonner Springs, Kans.) crushed conditioned pellets 0.50% NaOH 210 (CS) 9.1 (FS) 12.1 ND ND ND (NO VALUE) (CS) __________________________________________________________________________ FS--Cylinder fell apart in four hour water soak. ND--Not determined.
TABLE 18 __________________________________________________________________________ AMOUNT OF MOISTURE MOISTURE MOISTURE ADDITIVE STRENGTH "A" CONTENT % STRENGTH "B" CONTENT % STRENGTH "C" CONTENT "E" __________________________________________________________________________ Mixtures made from cement kiln dust from California Portland (Colton, Calif.) with Fly Ash from Western Ash Co. and France Aggregate (Color 2, Class "F") 0.75% CaO 1385 (CS) 8.5 960 (CS) 8.7 345* (CS) 11.3 80 Mixtures made from cement kiln dust from SME Cement (Middlebranch, With Toledo Edison Bay Shore Fly Ash Aggregate and France 0.75% CaO** 1815 (CS) 9.3 650 (CS) 8.8 345* (CS) 11.3 820 0.75% CaO*** 1580 (CS) 9.8 650 (CS) 8.8 345* (CS) 11.3 585 __________________________________________________________________________ *The cylinders containing CaCO.sub.3 as a substitute for kiln dust used Trenton Channel Fly Ash. **CaO slurry cooled for 20 minutes ***CaO mixed with water for one minute before adding to dry blend
TABLE 19 __________________________________________________________________________ AMOUNT OF MOISTURE MOISTURE MOISTURE ADDITIVE STRENGTH "A" CONTENT % STRENGTH "B" CONTENT % STRENGTH "C" CONTENT "E" __________________________________________________________________________ Cement kiln dust from SME Cement (Toledo, Ohio) with Toledo Edison Bayshore Fly and France Aggregate 0.75% CaO 2050 (CS) 10.1 1380* (CS) 7.7 345** (CS) 11.3 325 Cement kiln dust from Columbia Cement (Zanesville, Ohio) (Precipitator Dust) with Fly Ash from Monier Resources and France Aggregate (Cincinnati, Ohio) 0.75% CaO 1410 (CS) 5.5 915* (CS) 10.2 345* (CS) 11.3 150 __________________________________________________________________________ *The cylinders without additive were made from an 88-84 mix. **The cylinders made with CaCO.sub.3 as a substitute for kiln dust used Trenton Channel Fly Ash and were made from an 88-84 mix. The values in th last column should be interpreted with caution as the mix designs were no all the same (68-86 vs. 88-84) and the fly ash in the CaCO.sub.3 cylinder was not the same as was used in the cylinders containing kiln dust.
______________________________________ Range of Values of "Synergistic Effect" (psi) Amount and Type of Additive (CS) (VS) ______________________________________ 0.25% CaO 265 * 0.50% CaO 280 160 0.75% CaO 550 495 1.14% CaO 345 315 1.50% CaO 115 -130 0.75% Ca(OH).sub.2 500 240 1.50% Ca(OH).sub.2 170 70 3.0% Ca(OH).sub.2 -110 60 ______________________________________ *Only Compressive strength run on this addition.
______________________________________ Range of Values of "Synergistic Effect" (psi) Amount and Type of Additive (CS) (VS) ______________________________________ 0.75% CaO 90 470 1.14% CaO 95 645 1.50% CaO 55 145 0.75% Ca(OH).sub.2 420 170 1.50% Ca(OH).sub.2 1110 575 3.0% Ca(OH).sub.2 270 370 ______________________________________
______________________________________ Values of "Synergistic Effect" (psi) Amount and Type of Additive (CS) ______________________________________ 0.38% CaO -25 0.76% CaO 555 1.14% CaO 155 0.75% Ca(OH).sub.2 265 1.50% Ca(OH).sub.2 100 ______________________________________
______________________________________ Range of Values of "Synergistic Effect" (psi) Amount and Type of Additive (CS) (VS) ______________________________________ 0.25% CaO 310 330 0.50% CaO 125 160 0.75% CaO 240 270 1.14% CaO -380 35 1.50% CaO 130 -440 0.75% Ca(OH).sub.2 -70 -230 1.50% Ca(OH).sub.2 65 -80 3.0% Ca(OH).sub.2 50 -195 ______________________________________
______________________________________ Range of Values of "Synergistic Effect" (psi) Amount and Type of Additives (CS) (VS) ______________________________________ 0.25% CaO -45 -215 0.50% CaO -235 175 0.75% CaO 685 355 1.14% CaO 515 360 1.50% CaO 430 830 0.75% Ca(OH).sub.2 415 -45 1.50% Ca(OH).sub.2 400 420 3.0% Ca(OH).sub.2 380 950 ______________________________________
______________________________________ Range of Values of "Synergistic Effect" (psi) Amount and Type of Additives (CS) (VS) ______________________________________ 0.75% CaO 395 745 1.14% CaO 195 370 1.50% CaO 240 320 0.75% Ca(OH).sub.2 445 530 1.50% Ca(OH).sub.2 240 -25 3.0% Ca(OH).sub.2 315 755 ______________________________________
______________________________________ Range of Values of "Synergistic Effect" (psi) Amount and Type of Additive (CS) (VS) ______________________________________ 0.75% CaO 535 600 1.14% CaO 550 595 1.50% CaO 595 500 0.75% Ca(OH).sub.2 480 385 1.50% Ca(OH).sub.2 960 755 3.0% Ca(OH).sub.2 820 800 ______________________________________
______________________________________ Values of "Synergistic Effect" (psi) Amount and Type of Additive (CS) ______________________________________ 0.38% CaO 240 0.76% CaO 635 1.14% CaO 805 0.75% Ca(OH).sub.2 745 1.50% Ca(OH).sub.2 530 ______________________________________
______________________________________ Range of Values of "Synergistic Effect" (psi) Amount and Type of Additive (CS) (VS) ______________________________________ 0.75% CaO -415 395 1.14% CaO -260 -85 1.50% CaO -670 -830 0.75% Ca(OH).sub.2 -560 -470 1.50% Ca(OH).sub.2 -550 -490 3.0% Ca(OH).sub.2 -845 -665 ______________________________________
______________________________________ Range of Values of "Synergistic Effect" (psi) Amount and Type of Additive (CS) (VS) ______________________________________ 0.75% CaO -620 -355 1.00% CaO -1195 -790 1.50% CaO -1305 -735 0.75% Ca(OH).sub.2 95 -255 1.50% Ca(OH).sub.2 -5 -525 3.0% Ca(OH).sub.2 -30 -20 ______________________________________
______________________________________ Range of Values of "Synergistic Effects" (psi) Amount and Type of Additive (CS) (VS) ______________________________________ 0.75% CaO -1055 -1795 1.14% CaO -1705 -1545 1.50% CaO -1315 -1380 0.75% Ca(OH).sub.2 -485 -1715 1.50% Ca(OH).sub.2 -865 -1970 3.0% Ca(OH).sub.2 -1700 -2395 ______________________________________
______________________________________ Range of Values of "Synergistic Effect" (psi) Amount and Type of Additive (CS) (VS) ______________________________________ 0.75% CaO 535 85 1.14% CaO -5 -265 1.50% CaO 225 -550 0.75% Ca(OH).sub.2 715 -155 1.50% Ca(OH).sub.2 730 -570 3.0% Ca(OH).sub.2 -195 -430 ______________________________________
______________________________________ Range of Values of "Synergistic Effects" (psi) Amount and Type of Additive (CS) (VS) ______________________________________ 0.75% CaO 110 255 3.0% CaO ND* 0.75% Ca(OH).sub.2 220 305 1.50% Ca(OH).sub.2 505 270 3.0% Ca(OH).sub.2 80** -- ______________________________________ *ND. Not determined a mixture with 3.0% CaO added to CaCO.sub.3 as substitute for kiln dust was not made. **Only the compressive strength was measure for this addition.
______________________________________ Values of Amount and Type of Additive "Synergistic Effect" (psi) ______________________________________ 0.76% CaO 200 1.14% CaO -85 ______________________________________
______________________________________ Range of Values of "Synergistic Effect" (psi) Amount and Types of Additive (CS) (VS)* ______________________________________ 0.25% CaO 30 175 0.50% CaO 200 210 ______________________________________ *Initially only the compressive strengths of cylinders made from this mixture without additives were measured; therefore, the vacuum saturation strengths were compared to this to obtain the "synergistic effect".
__________________________________________________________________________ SUMMARY OF TESTS CYLINDER MAXIMUM SYNERGISTIC MAXIMUM SYNERGISTIC STRENGTH EFFECT USING CaO EFFECT USING Ca(OH).sub.2 TYPE OF CEMENT WITHOUT (psi) AT A GIVEN (psi) AT A GIVEN KILN DUST SOURCE OF DUST ADDITIVE AMOUNT OF ADDITION AMOUNT OF __________________________________________________________________________ ADDITION Marginal Dusts General Portland 580 (CS) 550 (CS)(0.75%) 500 (CS)(0.75%) (Chattanooga) 635 (VS) 495 (VS)(0.75%) 240 (VS)(0.75%) River Cement 675 (CS) 95 (CS)(1.14%) 1110 (CS)(1.50%) (Festus, MO) 725 (VS) 645 (VS)(1.14%) 575 (VS)(1.50%) Lone Star 0 (VS) 555 (CS)(0.75%) 265 (CS)(0.75%) (Dixon, IL) Separated Columbia Cement 1130 (CS) 310 (CS)(0.25%) 65 (CS)(1.50%) Dusts (Zanesville) 1065 (VS) 330 (VS)(0.25%) -80 (VS)(1.50%) SME Cement 1510 (CS) 200 (CS)(0.50%)** ND (Silica, Ohio) 1510 (VS) 210 (VS)(0.50%)** ND Conditioned Lone Star 0 (CS) 685 (CS)(0.75%) 415 (CS)(0.75%) Dusts (Bonner Springs) 0 (VS) 830 (CS)(1.50%) 950 (VS)(3.0%) (Conditioned Crushed Conditioned at Plant) Pellets Martin-Marietta 490 (CS) 395 (CS)(0.75%) 445 (CS)(0.75%) (Tulsa, OK) 355 (VS) 745 (VS)(0.75%) 755 (VS)(3.0%) Conditioned Dust (Conditioned River Cement 270 (CS) 755 (CS)* ND in Laboratory) (Festus, MO) (Marginal Dust) Columbia Cement 515 (CS) 360 (CS)* ND (Zanesville) (Separated Dust) Separated General Portland 0 (CS) 595 (CS)(1.50%) 960 (CS)(1.50%) and (Tampa, FL) 0 (VS) 600 (VS)(0.75%) 800 (VS)(3.0%) Conditioned Crushed Conditioned Dust Pellets Dundee Cement 145 (CS) 805 (CS)(1.14%) 745 (CS)(0.75%) (Clarksville, MO) __________________________________________________________________________ *Result of 0.75% CaO addition. ND Test on this additive not run. **Only additions of 0.25% and 0.50% studied.
TABLE 20 __________________________________________________________________________ Cross-Sectional Weight Percentages of Cement Area Compressive Moisture Kiln Dust - Fly Ash - Desul- Machine of Strength Wet Unit Content furization Scrubber Sludge Cylinder Load Cylinder (psi) Weight (%) and Additive No. (lb) (in.sup.2) (73° F. - 76 days) (lb/ft.sup.3) (Wet Basis) __________________________________________________________________________ 8-16-76, No Additive #1 220 12.55 18 88.5 49.8 7-16-76.25 + 0.75% CaO #1 520 12.55 41 88.8 50.9 13-15-72, No Additive #1 660 12.59 52 88.5 45.8 12-15-72 + 1% CaO #2 2470 12.55 197 90.0 47.4 __________________________________________________________________________
______________________________________ Sample 1 Sample 2 Sample 3 ______________________________________ Moisture Content, % Initial 89.8 87.0 73.5 Final 93.2 85.5 77.7 Wet Unit Weight, pcf Initial 94.4 97.0 96.0 Final 96.1 96.2 98.3 Dry Unit Weight, pcf Initial 49.7 51.9 55.3 Back Pressure Saturation, psi Pressures 10.0 10.0 10.0 Permeability, cm/sec k 5.6 × 10.sup.-8 4.1 × 10.sup.-6 4.7 × 10.sup.-7 ______________________________________
TABLE 21 Description of Lone Weight Percent- Sectional Compressive Percentage of Star (Bonner Springs, ages of CKD - Machine Area of Strength Wet Unit Moisture Dry Unit Maximum Dry Kans.) Cement Kiln Source of FA - Aggregate Cylinder Load Cylinder (psi) Weight Content Weight Unit Weight Dust Fly Ash + Additive No. (lb) (in.sup.2) (100° - 7 days) (lb/ft.sup.3) (%) (lb/ft.sup.3) (129.6 = 100%) Fresh Dust Toledo Edison 8-8-84, #1 14,900 12.91 1155 137.7 8.9 126.4 97.5 Bay Shore No additive #2 10,400 12.83 810 136.8 8.8 125.7 97.0 #3 13,300 12.95 1025 139.2 8.8 127.9 98.7 Average = 995 137.9 8.8 126.7 97.8 Fresh Dust Toledo Edison 8-8-83.25 + #1 24,100 12.91 1865 142.8 10.2 129.6 100.0 Bay Shore 0.75% CaO #2 24,300 12.87 1890 142.2 10.1 129.2 99.7 #3 23,600 12.95 1820 142.5 10.3 129.2 99.7 Average = 1860 142.5 10.2 129.3 99.8 Fresh Dust Class "F" 7-8-84.25 + #1 19,300 12.91 1495 137.1 9.1 125.7 97.0 Supplied 0.75% CaO #2 21,300 12.87 1655 136.8 9.1 125.4 96.8 by Superior #3 21,500 12.87 1670 138.0 9.3 126.3 97.5 Asphalt Average = 1605 137.3 9.2 125.8 97.1 Fresh Pellets Toledo Edison 8-8-84 #1 FS 12.63 -- (FS) 139.5 9.6 127.3 98.2 (Crushed) Bay Shore No additive #2 FS 12.67 -- (FS) 138.9 9.1 127.3 98.2 #3 FS 12.63 -- (FS) 138.3 9.4 126.4 97.5 Average -- (FS) 138.9 9.4 127.0 98.0 Fresh Pellets Toledo Edison 8-8-83.25 + #1 14,900 12.67 1175 136.2 9.2 124.7 96.2 (Crushed) Bay Shore 0.75% CaO #2 14,900 12.63 1180 137.1 9.3 125.4 96.8 #3 10,900 12.67 860 135.9 9.0 124.7 96.2 Average = 1070 136.4 9.2 124.9 96.4 Fresh Pellets Class "F" 7-8-84.25 + #1 14,600 12.95 1125 139.2 9.9 126.7 97.8 (Crushed) Supplied 0.75% CaO #2 14,800 12.83 1155 140.1 10.4 126.9 97.9 by Superior #3 15,000 12.79 1175 140.1 10.0 127.4 98.3 Asphalt Average = 1150 139.8 10.1 127.0 98.0 30 Day Old Pellets Toledo Edison 8-8-84 #1 BC ND -- (BC) 139.8 10.2 126.9 97.9 (Crushed) Bay Shore No additive #2 BC ND -- (BC) 139.8 10.2 126.9 97.9 #3 BC ND -- (BC) 139.8 10.4 126.6 97.7 Average = -- (BC) 139.8 10.3 126.8 97.8 30 Day Old Pellets Toledo Edison 8-8-83.25 + #1 10,800 12.87 840 141.6 11.3 127.2 98.1 (Crushed) Bay Shore 0.75% CaO #2 10,400 12.83 810 141.0 11.3 126.7 97.8 #3 11,100 12.91 860 141.0 11.3 126.7 97.8 Average = 835 141.2 11.3 126.9 97.9 30 Day Old Pellets Class "F" 7-8-84.25 + #1 14,400 12.91 1115 141.6 10.5 128.1 98.8 (Crushed) Supplied 0.75% CaO #2 14,100 12.95 1090 142.2 10.7 128.5 99.2 by Superior #3 14,300 12.91 1110 142.2 10.1 129.2 99.7 Asphalt Average = 1105 142.0 10.4 128.6 99.2 Two Year Old Pellets Toledo Edison 8-8-84 #1 FS 12.83 -- (FS) 141.9 9.6 129.5 99.9 (Crushed) Bay Shore No additive #2 FS 12.91 -- (FS) 134.7 9.8 122.7 94.7 #3 FS 12.99 -- (FS) 139.5 10.4 10.4 97.5 Average = -- (FS) 138.7 9.9 126.2 97.4 Two Year Old Pellets Toledo Edison 8-8-83.25 + #1 13,700 12.91 1060 141.3 9.4 129.2 99.7 (Crushed) Bay Shore 0.75% CaO #2 13,500 12.95 1040 141.0 9.2 129.1 99.6 #3 13,600 12.91 1055 141.3 9.5 129.0 99.5 Average = 1050 141.2 9.4 129.1 99.6 Two Year Old Pellets Class "F" 7-8-84.25 + #1 12,100 12.8* 940 142.5 10.5 129.0 99.5 (Crushed) Supplied 0.75% CaO #2 13,100 12.8* 1015 142.8 10.6 129.1 99.6 by Superior #3 7,900** 12.8* 610** 140.4 10.6 126.9 97.9 Asphalt Average = 855 141.9 10.6 128.3 99.0 BC--Cylinder broke while removing from capper. ND--Not determined. FS--Cylinder fell apart in four hour water soak. *The circumference of the cylinder was not measured. The compressive strength was calculated from a crosssectional area of 12.8 in..sup.2 **The low strength of this cylinder could have been caused by a horizonta crack.
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